Toroidal coil-winding machine for deflection yoke coils for television picture tubes and the like

ABSTRACT

A machine for winding toroidal coils useful for yokes of television picture tubes having an air motor for loading the magazine and for winding the coil under uniform tension. An indexing mechanism comprising an index plate under control of a double-throw pawl effects precisely located winding turns on the inner face of the toroidal yoke core facing the outer surface of the television picture tube. The index plate of the indexing means is arranged for a plurality of different winding configurations and in combination with the double-throw pawl winding assures accurate and precise winding without damage to the teeth of the index plate.

United States Patent a corporation of New Jersey TOROIDAL COIL-WINDING MACHINE FOR DEFLECTION YOKE COILS FOR TELEVISION PICTURE TUBES AND THE LIKE 5 Claims, 9 Drawing Figs.

US. Cl 242/4 Int. Cl HOlf 41/08 Field of Search 242/4, 5,6;

Primary Examiner- Billy S. Taylor Attorney-Rauber & Lazar ABSTRACT: A machine for winding toroidal coils useful for yokes of television picture tubes having an air motor for loading the magazine and for winding the coil under uniform tension. An indexing mechanism comprising an index plate under control of a double-throw pawl effects precisely located winding turns on the inner face of the toroidal yoke core facing the outer surface of the television picture tube. The index plate of the indexing means is arranged for a plurality of different winding configurations and in combination with the doublethrow pawl winding assures accurate and precise winding without damage to the teeth of the index plate.

5 zwgppl 1 PATENTEDFEB 2:911 9559.999

SHEET 1 OF 4 F I INVENTOR.

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INVENTOR. RUDOLF FAl-IRBA CH TOROIDAL COIL-WINDING MACHINE FOR DEFLECTION YOKE COILS FOR TELEVISION PICTURE TUBES AND THE LIKE BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to winding and reeling and more particularly to machines for winding toroidal coils for television picture tubes.

2. Description of the Prior Art Heretofore winding machines for toroidal coils provided for winding turns on a generally random basis where the respective turns were applied to the surface of the toroidal core in helical manner by rotating the core relative to the shuttle or magazine interlinked therewith. In certain applications it became necessary to effect precise winding turn location on the core, such as in a recess on the surface thereof through which a portion of the winding turn is passed, owing to the ever increasing precision of location and their resulting electromagnetic fields produced by such windings as needed in the color television picture tube art.

Furthermore, it has become an additional problem to assure accurate center line location of the core relative to the shuttle magazine so that each turn wound upon the core is precisely longitudinal relative to the core.

In addition indexing devices used heretofore have been found wanting in reliability owing to the repeated breakage of the teeth used for indexing purposes.

It is the general object of the present invention to overcome these difficulties by providing a winding machine that indexes the individual turns of any of a plurality of windings in a precise accurate manner that is accurately reproduced for each successive use of the machine for mass production facilities.

It is a still further object of the invention to provide for means to accurately center the core relative to the winding magazine whereby an accurately oriented winding turn is placed on the core.

A still further object of the invention is to provide means utilizing an air motor for producing a rapid loading of the magazine and a tension winding of the strand or wire that minimizes breakage.

SUMMARY OF THE INVENTION According to the invention, a winding machine is provided for a magazine suspended within six rollers centered with respect to the mounting frame to carry the magazine and shuttle gear in balanced symmetrical roll and yet allows for withdrawing the wire from the magazine precisely in a center plane of the winding head to wind the wire on the core precisely longitudinal of the core.

One of the six rollers is a roller that is driven by an air motor for loading the magazine in one direction of rotation and for tensioning the magazine during its idling operation while the core is being wound. Another roller of the six rollers is driven by a conventional gear train for driving the gear ring of the winding head.

The indexing assembly comprises an indexing plate having a plurality of precisely located teeth for engaging a pawl which rotates the plate by engaging the teeth. The pawl is arranged for a double acting pivot (termed herein the double-throw pawl) so arranged to engage the service of each tooth without striking the sidewalls of each tooth on both the drive and withdrawal action.

BRIEF DESCRIPTION OF THE DRAWING Referring now to the attached drawing wherein:

FIG. 6 is a side elevation view of the core clamp assembly;

FIG. 7 is a side elevation partly in section of the centrifugal cutoff;

FIG. 8 is a detail of the idler-roller; and

FIG. 9 is an isometric view of a core 30 showing the serrations and several of the coil windings thereon.

Referring initially to FIG. I, there is shown a winding machine 10 comprising a base 12, a C-frame 14 carrying four idler rollers 16 and two drive rollers 18 and 20.

An air motor 22 drives the roller 20 in one direction and is arranged to provide a friction drag for roller 20 in the reverse direction of rotation. The drive roller 18 is driven by a conventional gear train enclosed within the housing 24 actuated by the drive system of the winding machine, not shown, in the conventional manner. Supported within the six rollers l6, l8, and 20, is a winding gear 26 and a magazine 28 provided with the usual removable segment portion, not shown, for receiving a core in interlinked relation, as is well known in the art. The core 30 is shown in position interlinked with the gear ring 26 and magazine 28 supported by a core clamp 32 mounted on the upper surface of index plate 34, as by bolt 36 centrally located thereon. A wire guide 38 mounted on the C-frame I4 guides wire loaded on the magazine 28 therefrom onto the core 30.

The core 30 is shown in FIG. 9 in perspective showing the several windings each have a plurality of turns and each turn of which is guided through the grooves of the serrations formed on the respective flat ends of the core.

Index plate 34 is provided with the series of notches 35 disposed in a peripheral portion of the plate each series corresponding to the desired winding pattern with respect to the number of turns and location relative to the other series of windings to be placed on the core 30. In a preferred form of coil-winding array, four separate coil windings are placed on the core 30. Each of the four coil windings has a unique loca- FIG. 1 is an isometric view of one embodiment of the invention on the core, and is programmed for its winding pattern by a separate index plate 34. Thus, each core 30 must be wound four separate times, each time a different index plate 34 being placed on the machine by simply removing the screw 36 and interchanging the index plates as required.

The index plate 34 is rotated in synchronism with the rotation of the gear and magazine rings 26 and 28. Each rotation of the rings causes one turn of the winding to be placed at the core 30 in the manner known in this art. The core, in the preferred form of the type found in contemporary color television systems, is provided with recesses 42 and 44 formed as serrations or grooves on the end faces thereof for receiving each turn of the winding. In this manner the precise and accurate location of each winding turn can be consistently and uniformly determined for each core. Each winding turn placed in the respective recesses at the core 30 is synchronized with the stepwise rotational movement of the index plate 34.

The plate 34 is rotated in synchroiiism with the rotation of the winding rings by means of an indexing assembly, not shown, located below the base 12 of the machine. The indexing assembly is of any suitable type powered by the electric motor of the machine causing the index plate 34 to rotate in a single direction such as the c.w. direction about the axis of bolt 36.

In order to assure the positive and correct location of the core 30 during the time the wire is being wound from the magazine 28 over the wire guide 38 to the core 30, means are provided for holding or restraining the index plate in position during the winding phase and allowing it to advance to the next winding turn position by the double-acting pawl assembly. Referring now particularly to FIGS. 2, 3, 4 and 5, there is shown in the several views the double-acting or double-throw pawl assembly 40 for accomplishing these functions.

The pawl assembly 40 consists of a base portion 46 of generally rectangular form having a vertical flange 48 for supporting the manual lever 50 which pivots about the axis 52. The actuating members of the assembly include the pawl body 54 and the pawl tip 56. The respective shapes of the pawl tip and pawl body are such as to cause the pawl tip to be displaced in a substantially radial direction with respect to the index plate 34 in response to movement of the pawl body 54.

The pawl body 54 is connected to a spherical bearing 58 carried within a shoulder stud 60 with its shaft connected for pivotal movement with a rod 62. Rod 62 is suitably pivotally connected to the lever 50 about the common axis 64 as with a fork stud.

Pawl body 54 is arranged to pivot about a screw 66 journaled within an extension portion 55 of the pawl body 54. The pawl tip 56 pivots about a pin 68 mounted on body portion 53 of the pawl body 54. A screw 70 attached to the pawl tip 56 secures one end of a tension spring 72, the other end of which spring is connected to a screw 74 connected to the pawl body 54. A setscrew 76 with an adjustment locking nut 78 is mounted on a portion of the pawl body 54 for limiting the pivotal movement of the pawl tip relative to the pawl body 54. The dotted lines in FIG. show the position of the pawl tip 56 in the withdrawn position.

It should be noted that the center line of the pivot screw 66 is colinear with the extreme end of the tooth point S7 of the pawl tip 56 with a line inwardly displaced and parallel with the tangent to the plate at the radial end of the notch. According to the invention this precise relationship of the location of the pawl body pivot assures the desired radial movement of the pawl tip 56 repeatedly and accurately without damaging the index teeth as occurred heretofore, and also prevents the index plate 34 from moving in the opposite direction if the pawl point 57 were to pivot against the radial wall of the notch 35.

It should be appreciated in accordance with the principle of the invention that the pivot point 66 of the pawl unit is located to prevent a movement of the tooth 56 in a direction opposite to the rotation of the plate 34. To accomplish this movement the pivot point 66 is preferably located at the place described, but may be displaced radially inwardly within the limits of the choice of the designer.

The double-action pawl movement is effected by the reciprocal action of the rod 62 supported in the base 12 of the machine. The rod 62 is connected to a bearing 79 provided with a threaded stud rod 80 connected to the rod 62 by a turnbuckle 82. By this arrangement the effective length and movement thereby of the rod 62 may be adjusted. A triangular plate 84 is pivotally connected at 90 to an angle bracket 86 rigidly attached to the base 12 as by screw 88. The pivotal connection at 90 effects a vertical movement of the rod 62 by the pivotal action of the spherical bearing 92 connected to the plate 84 and seated within the end rod 80. Joumaled within a yoke portion 94 of the plate 84 is a roller 96. The roller 96 functions as a cam follower riding on a cam 98 provided with a short lobe 99. The cam 98 is rotated, by means not shown, in direct synchronization with the rotation of the winding gear 26 and magazine 28. Thus each rotation of the winding rings which cause a turn of wire to be placed on the core 30 causes the pawl mechanism to be actuated. As the cam 98 rotates causes the roller 96 to effect a vertical movement of the rod 62, the lever 50 and the stud 60 are caused to rotate respectively clockwise and counterclockwise relative to the axis 64 which is being displaced upwardly. The stud 60 carrying the spherical bearing 58 is caused to pivot to the left as seen in FIG. 2, that is, in a direction radially inwardly of the index plate 34. The pawl body 54 thereby is pivoted about screw 66 and in turn causes the pawl tip 56 to be displaced radially outwardly from its seated position within a tooth 35 from the seated posi tion as seen in FIG. 5.

The pawl point 57 is now free to pivot about pin 68 and is urged outwardly by the expansion spring 72. The pawl tip 77 is constrained from significant nonradial deflection by the setscrew 76 striking the sidewall of the pawl tip 56 after a very small incremental movement.

The cam 98 is so shaped as to allow the desired movement of the bearing 60 and the pawl body 54. The spring 63 is arranged to return the rod 62 to its lower position when the roller 96 is clear from the high portion of the cam 98. The pawl tip upon striking the setscrew 76 reacts against the pivot 66 on the pawl body 56 to cause the pawl assembly to pivot inwardly. The rod 62 it is noted is free to be forced downwardly aided by the spring 63 since the cam 98 has rotated clear of the roller 96. Thus, the action of the setscrew 76 striking the pawl tip 56 in cooperation with the expansion spring 72 causes the pawl tip 56 to be reseated accurately and rapidly within the next available tooth which is advanced to the position of the pawl tip by rotation of the index plate 34.

Referring now to FIG. 6, the details of the core clamp assembly 32 illustrate in side elevation the quick acting resilient core-holding clamp of the invention. The core clamp 32 includes a base portion 100 attached to the index plate 34 by'a screw 33. The recessed bore 36a receives the screw 36 about which the index plate is rotated. The vertical rib 102 is provided with a narrowed neck portion 104 for carrying a short jaw 106 rigidly mounted thereon. The jaw 106 is provided with a recessed end portion 106a for holding the large diameter portion of the core 30. A longer jaw 108 has a similar recessed end portion thereof for holding the shorter diameter portion of the core 30 and is fixed to the assembly as at bolt 110. A manual lever 112 is pivotally connected within one end of a rod housing 114 which in turn is rigidly mounted to the clamp assembly by pin 116. The lever 112 includes a cam 118 arranged to ride on a pistonhead 120. A spring 122 presses against the upper surface of jaw 108. Another spring 123 is connected to the lower surface of jaw 108 at 121 and is connected to the jaw 106 at 124.

ln operation,;when the lever 112 is moved upwardly, cam 118 is rotated to its low position to thus release the spring 122 and 123 allowing the jaw 108 to be pivoted at bolt 1.10 to an open position releasing the core 30. A new core 30 placed in position at the respective ends of the jaws 108 and 106 can be quickly and accurately clamped in position by rotation of the lever l 12 back to the position as shown. Accordingto this feature of the invention the cores 30 are resiliently but firmly maintained in position during the winding operation. Accordingly, breakage that occurred with cores made of brittle or easily breakable material is avoided. Furthermore, the snap action from fully closed to fully released position by the simple pivotal movement of lever arm 112 provides for an effective and accurate means to rapidly replace the core 30 for each winding operation. The air motor 22 serves to drive the magazine 28 in the wire-loading direction under fulloperating pressure such as 10 to l5 pounds per square inch (p.s.i. During the unloading phase of the magazine, that is, during the phase the core 30 is being wound with turns of wire 11 taken from the magazine 28, the air motor 22 serves to brake the magazine under a reduced operating pressure such as 3 to 6 psi. Conventional means are provided to regulate the operating pressure of the air motor 22 and the electrical control circuits (not shown) are adapted to perform the required valving operations needed for the various phases of the winding operation.

FIG. 7 illustrates a means to cut off the air motor in the event the wire breaks from the supply source during the loading phase, that is, while the wire is drawn from the supply and wound on the magazine 28. ldler gear 126, suitably mounted in cooperation relative with the magazine 28 to be driven thereby, is conveniently mounted on the extension of the drive shaft for the shuttle drive gear 18. Gear 126 drives a gear 128 suitably mounted by a stud 130 and nut 132 on the C-frame 14. Gear 128 includes a boss 134 for earryinga pair of diametrically oriented pins 135 each having a head 136 and an annular weight 138 freely slidable over the pins 135 and of an outside diameter slightly larger than the pin heads 136. A spring 139 of suitable force urges the weights 138 radially inwardly.

A microswitch 140 is mounted on a bracket 142 and connected to the C-frame 14 by screws 144. The actuator 146 of the microswitch 140 is located to be clear of the path of rotation of the pin head 136 and yet so located as to be actuated by either of the weights 138 when driven outwardly along pin 135 by the centrifugal forces which overcome the force of springs 139.

During the loading of the magazine, a broken supply wire will cause the magazine to increase speed. The weights 138 will. due to the increasing speed, move radially outwardly until the spring force is overcome sufficiently to actuate the microswitch 140. Electrical controls, not shown, cause the air motor drive to be cut off automatically to thereby prevent damage to the machine components and for the safety of the operator.

FIG. 8 shows in detail one of the four idler support roller assembly 16. These rollers, together with the drive rollers 18 and 20, provide a six-position support of the magazine and shuttle gear in a substantially centered position. In order to provide a centered support for the shuttle gear 26 and magazine ring 28 so that the wire guided on the core 30 is in the central plane thereof, the C-frame 14 is provided with a rib 15 extending inwardly and slightly off center. A flange 150 is attached to the rib 15 by screw 152. A pair of rollers 154 and 156 are rollerbearing mounted on a shaft 158 having an enlarged central portion 160. A retaining ring 162 is fitted at each end of the shaft to hold the inner race of the roller bearings firmly in position. The channel recesses 164 and 166 receive flanges of the shuttle gear 26 and magazine 28 respectively. During operation the wire strand 11 is carried from the magazine 28 in a plane substantially centered between rollers 154 and 156 on the core 30 guided by wire guide 38 during the winding cycle as the strand is carried over the upper end of the core. In this manner the wire 1 1 applied to the inner face of core 30 in a substantially straight, radial line, assuring thereby a coil, such as used for television yokes, satisfies the very stringent accuracy required. Furthermore, since the idler rollers and the drive rollers are supported within the C-frame 14, there is obtained a symmetrical balance with no strain or twisting forces that occurred in previous machines which mounted the rollers on the side of the C-frame. This arrangement will allow a larger winding angle to approximately 320 of core rotation.

In operation, the core 30 is interlinked with both the shuttle 26 and magazine 28 in the usual manner and is clamped in position in core clamp 32. Wire 11 is drawn from a supply spool (not shown) and carried through a footage counter and cutoff device 13 over the wire guide roller 17 and then to the magazine 28. The air motor is operated at full air pressure of l0--l5 p.s.i. to rotate the magazine for drawing wire thereon for the desired length. The magazine is stopped and the wire end is cut and then attached to the core 30 in the usual manner.

The machine is then operated to actuate the gear train 24 to drive the shuttle gear 26 in the opposite direction of rotation as that of loading the magazine 28. The air motor 22 is set to operate on a reduced pressure of about 36 p.s.i. against the rotation of magazine 28. The shuttle gear drives the usual guide eyelet and roller (not shown) mounted on the shuttle 26 to draw the wire from the magazine. When the desired number of turns has been applied to the core, the machine is stopped manually or automatically according to the means provided therefor Each turn of wire applied to the core is accurately guided into each recess on the core and each inner leg of each turn is radial without any significant bias from the radial plane ot the core. While each turn is being applied to the core. the pawl a sembly 40 holds from rotation the index plate 34 carrying the core thereby assuring an accurate location of the wire As the next turn is to be wound on the core the index assembly drives the plate 34 to advance and rotate the core accurately and rapidly to the next turn position.

It will be obvious to those skilled in the art that certain changes may be made in the invention without departing from the spirit and scope thereof. and. therefore. the invention is not limited by that which is specifically illustrated in the drawing and described in the specification. but only as indicated in the accompanying claims.

I claim:

1. A toroidal coil-winding machine for television deflection yoke coils and the like, said machine having a magazine adapted to be loaded with wire and driven about its axis through a toroidal core, in combination:

a. an index plate having notched teeth on the periphery thereof with one radial inner face;

b. means for rotating said plate about an axis through the center of the core to be wound;

c. a core clamp mounted on said index plate for holding a core in fixed horizontal position relative to said plate; and

. pawl means having a pawl tip for engaging each tooth on said plate in sequence including a double-acting lever means for reciprocating said pawl tip in substantially radial direction relative to said index plate to avoid thereby engaging the sidewall of said teeth during relative movement of said pawl and plate.

2. A machine according to claim 1 wherein said core clamp comprises:

a. an upper and lower jaw for holding a core in fixed position;

b. a first spring for holding said upper jaw resiliently against said core;

0. a lever-actuated cam for compressing said spring in one position and expanding said spring in a second position; and

. a second spring connected between said jaws and adapted to be compressed when said first spring is compressed and to be expanded when said 6-position spring is expanded to thereby cause said jaws to rapidly separate when said first spring is expanded.

3. A machine according to claim 1 wherein an air motor rotates said magazine for the wire-loading phase at a high operating pressure and brakes said magazine during the corewinding phase at a low operating pressure.

4. A machine according to claim 3 including centrifugal cutoff means for stopping the rotation of said magazine when the rotation thereof exceeds a selected speed by rendering inoperative said air motor.

5. A machine according to claim 1 wherein said magazine is supported within a C-frame support by four idler rollers and two drive rollers, said rollers being mounted on a rib extending radially inwardly from the inner surface of said C-frame, said rollers being located to support said magazine in a substantially symmetrically balanced position relative to said C-frame and said core. 

1. A toroidal coil-winding machine for television deflection yoke coils and the like, said machine having a magazine adapted to be loaded with wire and driven about its axis through a toroidal core, in combination: a. an index plate having notched teeth on the periphery thereof with one radial inner face; b. means for rotating said plate about an axis through the center of the core to be wound; c. a core clamp mounted on said index plate for holding a core in fixed horizontal position relative to said plate; and d. pawl means having a pawl tip for engaging each tooth on said plate in sequence including a double-acting lever means for reciprocating said pawl tip in substantially radial direction relative to said index plate to avoid thereby engaging the sidewall of said teeth during relative movement of said pawl and plate.
 2. A machine according to claim 1 wherein said core clamp comprises: a. an upper and lower jaw for holding a core in fixed position; b. a first spring for holding said upper jaw resiliently against said core; c. a lever-actuated cam for compressing said spring in one position and expanding said spring in a second position; and d. a second spring connected between said jaws and adapted to be compressed when said first spring is compressed and to be expanded when said 6-position spring is expanded to thereby cause said jaws to rapidly separate when said first spring is expanded.
 3. A machine according to claim 1 wherein an air motor rotates said magazine for the wire-loading phase at a high operating pressure and brakes said magazine during the core-winding phase at a low operating pressure.
 4. A machine according to claim 3 including centrifugal cutoff means for stopping the rotation of said magazine when the rotation thereof exceeds a selected speed by rendering inoperative said air motor.
 5. A machine according to claim 1 wherein said magazine is supported within a C-frame support by four idler rollers and two drive rollers, said rollers being mounted on a rib extending radially inwardly from the inner surfacE of said C-frame, said rollers being located to support said magazine in a substantially symmetrically balanced position relative to said C-frame and said core. 